EUROMAINTENANCE JOURNAL - DNV Germany

well as the follow-up of the progress. In
addition, we pre-commissioned new system
components.
Moreover, our people offered support with
tie-ins and the implementation of adjustments
to static equipment. They were also
given the supervision in catalytic exchange
and the cleanup work. In other words: we
became a major link between production
on the one hand and the global executing
contractor on the other”.
Punching
The punching of new line systems has an
administrative and a construction angle
to it. Bakelants explains: “In the administrative
punch, our specialists check issues
such as the fl ow direction, the line’s
gradient, the drainage and bleeding options,
etc. They also check for errors: errors
between the isometrics (+/- 4,000)
and the P&ID (process- and instrumentation
diagram). Moreover, we must check
whether or not the lines are drawn according
to the appropriate line specifi -
cations.” The construction punch, or the
actual acceptance, follows as soon as
the administrative punch is completed. In
this phase, the experts of Profs for Industry,
together with those responsible for
the production and the contractor, accept
the various line parts prior to printing the
line. A punch list with A, B and C items is
drawn up after each acceptance.
Pre-commissioning
In order to make work manageable,
Profs for Industry subdivided the abovementioned
expansion project into 150
packages of work. A folder was created
for each work package. The folder
contained a sketch of the location, the
required PID schemes, the isometrics,
the technical data sheets of the systems
and the punch lists. “As Profs for Industry
we were given the authority to rinse
the line system, to check for cleanness
and to subsequently sign for acceptance.
Also, we had to supervise the assembly
of the components which had been disassembled
for the pre-commissioning.”
“It is worth mentioning that both BASF as
well as the global executing contractor
were happy to use the work packages
that our organisation had compiled,”
says Bakelants.
‘Tie ins’
Yet another substantial assignment consisted
in producing the approx. 1,800
so-called ‘tie ins’ during the maintenance
stop. In order to make this happen in a
structured manner, an expert of Profs for
Industry was present at all meetings regarding
the ‘tie ins’. During the meetings,
a decision model was utilized to determine
how the system had to be isolated
in order to be able to rinse it. At these
meetings, it was also decided whether
they had to make hot or cold cuts. From
each ‘tie in’, a separate meeting report
was drawn up and included in the work
result. All of the steps that were necessary
within the Primavera maintenance
system were included in this report.
Through this approach, the engineering
fi rm had to work according to the system
of BASF. In preparation of the shutdown,
Profs for Industry, therefore, created the
job folders for the engineering fi rm with
the total work preparation per ‘tie in’.
n During major projects such as a shutdown,
screening of personnel and cooperation
is of critical importance.
These work folders contained a P&ID, a
photograph, isometrics, a fl ow diagram,
etc. The job folders were extremely useful
for the engineering fi rm as well as for our
own specialists. For they had to monitor
progress during the shutdown and check
the safety, explains Bakelants.
Personnel
Although Profs for Industry is daily involved
in the abovementioned fi eld, it
remains important to screen the employees
prior to the start of each project.
“We screen our people, but so does the
customer,” enunciates Bakelants. We
mainly screen a person’s background
and his/her team spirit. Cooperation
during such projects is quite important.
“In order to make certain that our employees
stay current at all times, during
HIGHLIGHTS
each toolbox meeting their knowledge is
refreshed with a specifi c weekly theme.
We strive to familiarize our employees
with their new environment. We do this
by offering them as many courses and
training sessions as possible, such an
internship week for the operators of
our department. The courses and training
sessions also serve as a great opportunity
for people to get to know one
another.”